Fluid container pouch

ABSTRACT

A fluid container pouch has first and second opposing side walls forming at least one enclosed chamber between them, each side wall is comprised of a laminate material having at least two layers. A first layer of the laminate is sealant layer for sealing to a sealant layer of an opposed side wall. A second layer of the laminate provides a barrier between the contents of the pouch and its environment. Each of the first and second layers comprises a material having oriented structure, such that energy sufficient to tear the material will be directed in a predetermined direction across the material, and further that the oriented structures of the first and second layers are aligned with each other. At least one design weakness in the pouch operative to direct tearing energy in a direction aligned with the oriented structure of said first and second layers.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. patentapplication Ser. No. 10/078,870, filed 19 February 2002, now pending,the complete disclosure of which is hereby incorporated by reference forall purposes.

BACKGROUND OF THE INVENTION

[0002] 1. Field of Invention

[0003] The present invention is related generally to the field ofpackaging, and more particularly, to the packaging of fluids forconvenient storage, transportation, and use.

[0004] More specifically, the present invention relates to a novelbeverage container having a self-contained straw for ease ofconsumption.

[0005] 2. Description of Related Art

[0006] The use of a pliable pouch to store fluids for convenientstorage, transportation, and use is well known in the art. For example,such pouches may be used to store medical fluids for intravenousinfusion to a patient; or for purified water or saline in a first aidkit. Such pouches are also used in conjunction with beverages designedfor human consumption.

[0007] When used as a container, the problem arises of how to open thepackage, and thereafter use the contents without spillage. One commonsolution in the beverage marketplace is to provide a wrapped straw witheach pouch, secured to the outside thereof. These straws are generallyrigid, and have a sharpened point at one end. Some predetermined andappropriately designated weak point of the pouch is punctured with thesharpened point of the straw, allowing consumption of the contents.

[0008] This arrangement has certain drawbacks. For example, the strawmay become separated from the pouch prior to its intended use. Forreasons of durability and preservation of the contents, so calledbarrier properties, such pouches are typically resilient, and difficultto tear open by hand. In that case, the package could only be openedwith great force, likely spilling the contents in the process.Therefore, it would be inconvenient to consume the contents if the strawwere separated.

[0009] Even if not separated, the wrapper of the straw may becomedamaged, compromising its hygiene and that of the contents when thestraw is inserted into the pouch.

[0010] U.S. Pat. No. 3,799,914 issued to Schmit, et al., discloses afluid pouch having a straw enclosed within it. However, to prevent fluidfrom flowing through the straw into an upper chamber, the straw must besealed by means of a complex folding procedure. This would necessitateexpenditure on labor or automated machinery to perform this task.

[0011] Further, the lower chamber must be sealed around the straw. Inproduction, it would be common for the straw to be irreversibly sealedin the process, for example, when heat is applied to seal the poucharound the straw as described. Thereafter, the straw, and consequentlythe pouch, would be unusable.

[0012] Other beverage pouches known in the art are taught, for example,by Darmstadter, U.S. Pat. Nos. 5,941,642 and 6,220,756-B1. Darmstadterteaches the inclusion of a straw within the pouch, however the pouch hasonly one chamber, and the straw is merely a straight straw, not aflexible straw. Consequently, it extends very little beyond the pouchwhen opened, and is therefore relatively inconvenient to use.

[0013] Another beverage pouch containing a straw is taught by Christine,et al., U.S. Pat. No. 5,564,591. Again, this straw is straight, notflexible, and extends very little beyond the pouch when opened. It islikewise inconvenient to use.

[0014] Moreover with respect to Christine, the pouch requires the strawto be broken prior to use, and the pouch also requires a sealed fitmentat an upper end of the straw.

BRIEF SUMMARY OF THE INVENTION

[0015] To overcome these and other difficulties in the prior art,disclosed is a fluid container pouch having a self-contained flexibledrinking or dispensing straw.

[0016] A fluid container pouch according to the present inventioncomprises at least first and second fluid chambers having at least twoflow channels for fluid communication between said first and secondfluid chambers. At least one of said flow channels comprises a flexibleconduit, such as a flexible drinking straw.

[0017] According to another aspect of the present invention, a fluidbeverage pouch is formed between opposing pliable sidewalls made of amaterial consisting of a polypropylene ply having a barrier layer on atleast one side.

[0018] In accordance with the present invention, a fluid container pouchis provided which is provided internally with a flexible straw. Thisallows for convenient and hygienic consumption of the beverage. Thisgoal is further achieved while preventing fluid from pooling in an upperchamber where a distal portion of a flexible straw is held without theneed for releasably sealing the straw in the packaging process, nor therisk of inadvertently permanently sealing the straw in the packagingprocess.

[0019] Further in accordance with the present invention, a beveragecontainer pouch is provided which achieves suitable barrier propertiesas compared with currently used materials for such purposes at asignificantly reduced cost.

[0020] According to a further embodiment of the present invention, afluid container pouch has first and second opposing side walls formingat least one enclosed chamber between them, each side wall is comprisedof a laminate material having at least two layers. A first layer of thelaminate is sealant layer for sealing to a sealant layer of an opposedside wall. A second layer of the laminate provides a barrier between thecontents of the pouch and its environment. Each of the first and secondlayers comprises a material having oriented structure, such that energysufficient to tear the material will be directed in a predetermineddirection across the material, and further that the oriented structuresof the first and second layers are aligned with each other. At least onedesign weakness in the pouch operative to direct tearing energy in adirection aligned with the oriented structure of said first and secondlayers.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] These and other features and advantages will become apparent fromthe following descriptions and drawings, where like numerals designatelike features across the several figures.

[0022]FIG. 1 shows a prospective view of a filled fluid container pouchaccording to the present invention;

[0023]FIG. 2 shows a side elevation view of the filled pouch;

[0024]FIG. 3 shows a front elevation view of an unfilled fluid containerpouch according to the present invention;

[0025]FIG. 4 shows a side elevation view of an unfilled fluid pouch;

[0026]FIG. 5 illustrates the flexible drinking straw used in conjunctionwith an exemplary embodiment of the present invention;

[0027]FIG. 6 shows a perspective view of a pouch according to thepresent invention after opening;

[0028]FIG. 7 shows a section view taken along line 7-7 of FIG. 6;

[0029]FIG. 7A shows the portion of FIG. 7 within circle 7A, 7B,according to one embodiment, enlarged and in additional detail;

[0030]FIG. 7B shows the portion of FIG. 7 within circle 7A, 7B,according to an alternate embodiment, enlarged and in additional detail;

[0031]FIG. 8 shows one embodiment of the pouch bearing indicia, shownagainst a dark background to highlight the pouch contours;

[0032]FIG. 9 shows a cross-section of the upper portion of the pouchaccording to a further embodiment, taken along line 9-9 of FIG. 3,including a resealable closure.

DETAILED DESCRIPTION OF THE INVENTION

[0033] Referring now to FIGS. 1 and 2, an exemplary embodiment of afilled fluid container pouch, generally 10, is illustrated. The pouchhas an upper portion 12, two lateral side portions 14, 16, and a lowerportion 18. First fluid chamber 20 and second fluid chamber 22 areprovided between opposing pliable walls 24 and 26. First fluid chamber20 and second fluid chamber 22 are generally separated by a margin 12 aformed in upper portion 12.

[0034] A flexible conduit, for example a flexible drinking straw 28, isprovided within the pouch 10 between the first chamber 20 and the secondchamber 22, forming a first flow path therebetween. The flexible strawis unsealed, and provides a first flow path 29 allowing fluidcommunication between the first chamber 20 and the second chamber 22. Asecond flow path 30 also allows fluid communication between the secondchamber 22 and the first chamber 20. In an exemplary embodiment, thesecond flow path 30 is coaxial with, and surrounds, the flexible straw28. In an alternate embodiment, second flow path 30 is a one-way flowpath permitting flow only from the second chamber 22 to the firstchamber 20.

[0035] One or more design weaknesses, e.g. tear notches 32 a and 32 b,are provided at upper portion 12 to allow the pouch to be torn open byhand. One or more through holes 34 a and 34 b are provided in upperportion 12 to allow the pouch to be hung from a rack, for example in aretail store aisle or refrigerated case.

[0036] Some portion of the pouch, upper portion 12 in the example ofFIG. 1, can be formed in a non-rectangular fashion such as defined byedges 35 a, 35 b. One method of doing this would be a die-cut press,other methods are known in the art. These cuts can be varied to conformto indicia printed on either or both walls 24, 26 of the pouch. Withreference to FIG. 8, in one exemplary embodiment, the indicia 110include a scene having mountains with clouds above the mountains. Theindicia 110 is printed on at least one wall, and the upper portion 12 ofpouch 10 is die cut to the shape of the clouds. Notch 32 b can be formedto match the indicia by a die-cut between a cloud above and a mountainslope below.

[0037] Referring now to FIGS. 3 and 4, the construction of the pouchwill be described in more detail opposing pliable walls 24 and 26 can beformed either by joining two sheets of a suitable material together andsealing the same along the upper portion 12, both lateral portions 14,16, and the lower portion 18. This can be accomplished either byheat-sealing, or any other suitable means known in the art. Theflexibility of the pliable wall material will allow the first chamber 20and second chamber 22 to form between opposing pliable walls 26 and 28when filled with a liquid.

[0038] An alternative, and preferred construction is to fold a singlesheet of the desired pouch material onto itself, and sealing along theupper portion 12, and both lateral portions 14, 16. More preferably,whether formed of two separate sheets or a single folded sheet, lowerportion 18 is provided with at least one gusset 36 to allow expansionfor additional fluid capacity, as well as to strengthen the seal at thelower portion 18. Additionally, either or both lateral portions may beprovided with gussets irrespective of any gusset 36 at a lower portion.

[0039] Pouch 10 may be constructed from a single layer material or amultiple layer material. Materials commonly used for beverage pouchesinclude a polyester ply sandwiched between layers of aluminum foil oneither side. While aluminum foil is generally considered an excellentbarrier, it has certain drawbacks. Among these, when the aluminum foilis flexed, micro and/or macro cracks develop easily in the surface,which severely compromise the barrier properties. Also, the aluminumfoil is exceedingly difficult to tear by hand, and if tearable, thedirection of the tear progresses randomly, necessitating other openingmethods as previously described.

[0040] Referring now to FIG. 7A, a more preferable material that wouldallow reduced cost without sacrificing barrier properties is apolypropylene film ply 101 having an oxygen barrier layer 103 on oneside only. The oxygen barrier layer 103 may be a metalized coating, analuminum foil layer, a polyethylene vinyl alcohol layer, or otherpliable material of suitable oxygen barrier properties known in the art.

[0041] This combination provides significant advantages. The oxygenbarrier layer 103 supplements the oxygen barrier properties of thepolypropylene. This is particularly important for carbohydrate-richbeverage liquids, where exposure to oxygen during shipment and storageadversely affects the contents' quality, even suitability forconsumption. Furthermore, the above barrier properties can be realizedat a reduced cost over the polyester material sandwiched between layersof aluminum foil as is commonly used.

[0042] With reference to FIG. 7A, the pouch 10 is preferably formed byorienting the oxygen barrier layer 103 outward. The outward facingbarrier layer allows the superior moisture barrier properties of thepolyethylene layer 101 to prevent contact between fluid contents of thepouch and the oxygen barrier layer, which could compromise theproperties of the oxygen barrier layer 103. Pouch 10 may then be formedby folding a single sheet of such material in the manner describedabove.

[0043] The choice of barrier layer materials may be influenced byaesthetic concerns without departing from the scope of the presentinvention. For example, a pouch having an outwardly facing metalized oraluminum foil oxygen barrier layer will have a reflective outer surface,which would allow attractive and eye-catching indicia to be applied. Useof polyethylene vinyl alcohol for the oxygen barrier has the advantageof transparency, which could be combined with a transparentpolypropylene layer to make the contents of the package visible.

[0044] In a more preferred embodiment, illustrated in FIG. 7B, amultiple ply laminate material comprises an innermost sealant layer 150.The sealant layer may comprise polyethylene, but other materials may besuitable. Polyethylene has the advantage of a low melting point.Therefore, two sheets of the sidewall material can be brought togetherwith respective sealant layers inward towards each other. Heat may beapplied from an external source, at a temperature above the low meltingpoint of the polyethylene, but below that of other layers. Therefore,the sealant layers melt together, forming a hermetic seal in region 152.The seal 152 exists only at the margins of the pouch 10, and the sealantply 150 is open to the first and second chambers 20, 22, where no sealis formed. In a more preferred embodiment, the polyethylene is linearlow density polyethylene (LLDPE). LLDPE is more rigid, and has improvedtearing characteristics, as described infra. In another embodiment, heatmay be applied to opposing sealant layers 150 before the two are broughttogether. Other sealing methods, including but not limited to folding,or application of solvent or adhesive may be substituted.

[0045] The preferred laminate material further comprises a barrier layer154, which is bonded to sealant layer 150 by an adhesive layer 156.Barrier layer 154 may itself comprise multiple layers. In the prior art,suitable barriers would include an aluminum foil layer. Polypropylene,though exhibiting other desirable qualities, is not ordinarilyconsidered to have acceptable oxygen barrier properties. However, recentadvances in materials technology have developed a compositepolypropylene material, which includes a vacuum deposited aluminum layeras part of a laminate material. An example of such material is marketedunder the OPPALYTE brand name by ExxonMobil Chemical Corporation, morespecifically designated Ultra-High Barrier 35 MU 842.

[0046] The material 35 MU 842 provides significant barrier to thepermeation of oxygen, water vapor, and flavor or aroma, previouslyunavailable in a polypropylene material. Additionally, as compared toother materials having similar barrier properties, for example a foiland polyester composite discussed above, the material 35 MU 842 retainsits barrier properties after being subject to flexing and/or folding.

[0047] To the exterior of the barrier layer 154, an additional adhesivelayer 158 bonds to an external layer 160. The external layer 160 maycomprise polyester, PET, oriented polypropylene, polyethylene or LLDPE,among other materials. The external layer 160 may be present to provideadditional puncture resistance or other generalized content protection,depending upon the selection of the other materials. In alternateembodiments, the external layer 160 and sealant layer 154 may beomitted. The exterior layer 160 may be reverse-printed on its innersurface to display indicia to its exterior surface, in a manner known inthe art.

[0048] The precise choice of materials will be dependent upon theparticular application, and more specifically the intended contents ofthe pouch and the requisite barrier properties. For example, an oxygenbarrier is desirable for a carbohydrate-rich beverage prepared withoutpreservatives. In another contemplated application, the pouch willcontain one or more doses of liquid pharmaceutical for medical delivery.Many medications, for example a cough medication, contain significantamounts of alcohol. Therefore, the pouch material must present asignificant barrier to at least alcohol and moisture. However, suchmedications are often preserved for extended shelf life, making oxygenbarrier less of a concern. In that case, other barrier materials may beprovided in place of, or in addition to, an oxygen barrier material.These include, but are not limited to, nylon, polyester, polystyrene,fluoropolymers and ethyl vinyl alcohol, among others. Each of the namedmaterials maintains orientation and tearability in accordance with otheraspects of the present invention. Other contemplated applications of thepresent invention include, but are not limited to, the dosing andapplication of pesticides. The particular pesticide in question willpresent needs for particular barrier properties, which will drive thematerial selection, without departing from the scope of the presentinvention.

[0049] Referring now to FIGS. 1, 6 and 7, the use of the beveragecontainer pouch will be described. In transportation and handling, thecontents may flow via the flexible straw 28 between the first chamber 20and the second chamber 22. It is, however, undesirable for fluidcontents to be pooled in the second chamber when the pouch is opened.For this purpose, second flow path 30 allows for any fluid conductedinto the second chamber 22 via flexible straw 28 to recycle back to thefirst chamber 20 under the influence of gravity via second flow path 30when the package is placed in an upright orientation, for example whenbeing opened. To aid in this recycling, a lower edge 40 of secondchamber 22 can be angled to bias any fluid within the second chamber 22towards the second flow path 30 and thereafter into the first chamber20.

[0050] To open the pouch, a user would tear the upper portion 12,beginning at a designated weakness, for example notch 32 b. Proceedingin the direction of arrow 100, the second chamber 22 would be openedalong tear line 204. Flexible straw 28 may be biased in a manner thatwill cause it to rise in the direction of arrow 102 once chamber 22 isfree of any downward constraints from upper portion 12. Therefore, anend of flexible straw 28 proximal to the user rises appreciably abovethe top of the pouch 10. The user may thereafter consume the beverage orotherwise use the contents.

[0051] It is a problem in the prior art that the features of a pouchthat make it resilient also make the pouch difficult to open in order touse or consume the contents. For example, aluminum foil, commonly usedin prior art pouches, is particularly resistant to puncture or tear.Therefore, according to one aspect of the present invention, thecomponents of a multi-ply laminate material have an oriented structure.More specifically, these oriented structures are aligned parallel witheach other and with the tear line 204. Tear line 204 is shown horizontalto the pouch 10, but it may traverse the pouch at any angle. The tearnotch 32 b concentrates the stress of the tearing energy along the tearline 204, and in conjunction with the parallel aligned orientation ofthe material structure, the tear progresses along the tear line 204 andacross the pouch.

[0052] Further, it is more preferable to have the tear line 204 transectan open portion of at least one chamber, in this case the second chamber22. In this way, as the tear progresses along the tear line 204, theuser need only tear two single plies for at least a portion of the tear,which presents less resistance than the margin portion where the twoopposing plies are sealed together.

[0053] In yet a further embodiment of the invention, referring to FIG.9, the pouch 10 is provided with a resealable closure 202 in the secondchamber 22. Resealable closure 202 may be of the tongue-and-groovevariety, wherein the seal is formed by the interface of a tongue portion202 a and a groove portion 202 b. Other resealing means known in the artmay be suitable as well. Resealable closure 202 is provided below thetear line 204 defined by notch 32.

[0054] In the case where flow path 30 is only a one-way flow path, thepouch may be inverted and/or squeezed for dispensing the contents. It isa further advantage to the present invention that providing the strawwithin the pouch, particularly across the diagonal dimension of thepouch as shown in the figures, enhances the structural stability of thepouch in all dimensions, particularly during handling andtransportation.

[0055] The invention has been described herein with reference toparticular exemplary embodiments. Certain alterations and modificationsmay be apparent to those skilled in the art, without departing from thescope of the invention. The exemplary embodiments are not meant to belimiting on the scope of the invention, which is defined by the appendedclaims.

To be secured by United States Letters Patent, what is claimed is:
 1. Asealed fluid container pouch comprising: a first enclosed fluid chamber;a second enclosed fluid chamber, said second fluid chamber beingelevated above said first fluid chamber when the pouch is upright; andat least two flow channels for fluid communication between said firstand second fluid chambers, wherein a first one of said at least two flowchannels comprises a drinking straw substantially traversing thecombined height of the first and second chambers.
 2. The fluid containerpouch according to claim 1 wherein said drinking straw comprises aflexible drinking straw.
 3. The fluid container pouch according to claim1 wherein an upper portion of said pouch comprises at least one throughhole.
 4. The fluid container pouch according to claim 1 furthercomprising one or more design weaknesses for allowing the pouch to betorn open.
 5. The fluid container pouch according to claim 1 wherein atleast one side of said second fluid chamber is angled to bias fluid flowtowards a second one of said at least two flow channels.
 6. The fluidcontainer pouch according to claim 1 wherein said pouch includes atleast one gusset for allowing the pouch to expand when filled.
 7. Thefluid container pouch according to claim 1 wherein a frontal profile ofsaid pouch is formed in a non-rectangular shape.
 8. The fluid containerpouch according to claim 7 wherein said non-rectangular shape conformsto indicia on at least one wall of said pouch.
 9. The fluid containerpouch according to claim 1 wherein said pouch is formed from a singlesheet of a pliable material folded onto itself and sealed along threesides.
 10. The fluid container pouch according to claim 9 wherein saidpliable material comprises a polypropylene ply and a barrier layer. 11.The fluid container pouch according to claim 10 wherein said barrierlayer comprises an aluminum layer.
 12. The fluid container pouchaccording to claim 10 wherein said barrier layer comprises a metalizedcoating.
 13. The fluid container pouch according to claim 10 whereinsaid barrier layer comprises a polyethylene vinyl alcohol layer.
 14. Thefluid container pouch according to claim 10 wherein said barrier layeris oriented outwardly.
 15. The fluid container pouch according to claim1 further comprising a resealable closure.
 16. The fluid container pouchaccording to claim 15, wherein said resealable closure is a tongue andgroove closure.
 17. The fluid container pouch according to claim 1,wherein said pouch comprises a laminate material having aligned orientedstructures.
 18. The fluid container pouch according to claim 1, whereinsaid pouch comprises a tearable oriented material that presents asignificant barrier to moisture.
 19. The fluid container pouch accordingto claim 1, wherein said pouch comprises a tearable oriented materialthat presents a significant barrier to oxygen.
 20. The fluid containerpouch according to claim 1, wherein said pouch comprises a tearableoriented material that presents a significant barrier to alcohols.
 21. Afluid container pouch comprising: first and second opposing side wallsforming at least one enclosed chamber between them, each side wallcomprised of a laminate material having at least two layers: a firstlayer of said laminate being a sealant layer for sealing to a sealantlayer of an opposed side wall; and a second layer of said laminatematerial providing at least a barrier between the predetermined contentsof the pouch and at least one component of its environment, wherein eachof said first and second layers comprises a material having orientedstructure such that energy sufficient to tear the material will bedirected in a predetermined direction across the material, and furtherthat the oriented structures of the first and second layers are alignedwith each other; and at least one design weakness operative to directtearing energy in a direction aligned with the oriented structure ofsaid first and second layers.
 22. The fluid container pouch according toclaim 21, wherein said laminate material further comprises a third layerfacing an exterior of the pouch.
 23. The fluid container pouch accordingto claim 21, wherein said third layer is reverse printed on an interiorsurface to show indicia to an exterior surface.
 24. The fluid containerpouch according to claim 21, wherein said third layer comprises amaterial selected from the group of polyester, PET, orientedpolypropylene, polyethylene and LLDPE.
 25. The fluid container pouchaccording to claim 21, wherein said second layer presents a significantbarrier to one or more of moisture, oxygen, and alcohol.